Barrier coatings for films and structures

Abstract

The invention provides coated substrates comprising a substrate; and a coating on at least one surface of the substrate comprising vermiculite, polymer capable of forming a film, dispersion agent for the vermiculite in the polymer, said dispersion agent bearing a negative charge, and cross-linking agent. The invention also provides articles coated with such coatings and methods for making the coated substrates and articles.

1. A coated film comprising:
 a base film; and 
 a coating on at least one surface of the base film comprising:
 (a) vermiculite; 
 (b) polymer capable of forming a film, said polymer comprising polyvinyl alcohol, ethyl vinyl alcohol copolymer, or blends thereof; 
 (c) dispersion agent for the vermiculite in the polymer, said dispersion agent being an anionic wax; and 
 (d) cross-linking agent; 
 wherein the weight ratio of dispersion agent to vermiculite is about 0.02 to about 0.45. 
 
 
     
     
       2. The coated film of  claim 1 , wherein said anionic wax is anionic polyethylene wax, anionic paraffin wax, anionic carnauba wax, or blends thereof. 
     
     
       3. The coated film of  claim 1 , wherein said anionic wax is anionic carnauba wax or a blend of anionic carnauba wax and anionic polyethylene wax. 
     
     
       4. The coated film of  claim 1 , wherein said anionic wax is a blend of anionic paraffin wax and anionic polyethylene wax. 
     
     
       5. The coated film of  claim 1 , wherein said anionic wax is anionic carnauba wax. 
     
     
       6. The coated film of  claim 1 , wherein the polymer comprises polyvinyl alcohol. 
     
     
       7. The coated film of  claim 1 , wherein the vermiculite has an aspect ratio of at least 5,000. 
     
     
       8. The coated film of  claim 1 , wherein the cross-linking agent is ethanedial, cyclic urea glyoxal condensate, or blends thereof; said cross-linking agent being present in an amount of 0.1 to 50 weight percent of the weight of said polymer capable of forming a film. 
     
     
       9. The coated film of  claim 1 , wherein the base film is polyethylene terephthalate, glycolised polyester (PET-G), nylon, biaxially oriented polypropylene, oriented polypropylene, cast polypropylene, polystyrene, polyethylene, polyvinyl chloride, polylactic acid (PLA), polyhydroxyalkanoate (PHA), polyvinyl chloride, or paper. 
     
     
       10. The coated film of  claim 1 , further comprising a sealant film contacting the coating. 
     
     
       11. The coated film of  claim 10 , wherein the sealant film comprises polyethylene or polypropylene. 
     
     
       12. The coated film of  claim 1 , having components that are FDA approved or FDA approvable for direct and/or indirect contact with food. 
     
     
       13. A composition comprising:
 (a) deionized water; 
 (b) vermiculite suspended therein; 
 (c) polymer capable of forming a film, said polymer comprising polyvinyl alcohol, ethyl vinyl alcohol copolymer, or blends thereof; 
 (d) dispersion agent for the vermiculite in the polymer, said dispersion agent being an anionic wax; and 
 (e) cross-linking agent; 
 wherein the weight ratio of dispersion agent to vermiculite is about 0.02 to about 0.45. 
 
     
     
       14. The composition of  claim 13 , wherein said anionic wax is anionic polyethylene wax, anionic paraffin wax, anionic carnauba wax, or blends thereof. 
     
     
       15. The composition of  claim 13 , wherein said anionic wax is anionic carnauba wax or a blend of anionic carnauba wax and anionic polyethylene wax. 
     
     
       16. The composition of  claim 13 , wherein said anionic wax is a blend of anionic paraffin wax and anionic polyethylene wax. 
     
     
       17. The composition of  claim 13 , wherein said anionic wax is anionic carnauba wax. 
     
     
       18. The composition of  claim 13 , wherein the polymer comprises polyvinyl alcohol. 
     
     
       19. The composition of  claim 13 , wherein the cross-linking agent is ethanedial, cyclic urea glyoxal condensate, or blends thereof; said cross-linking agent being present in an amount of 0.1 to 50 weight percent of the weight of said polymer capable of forming a film. 
     
     
       20. A coated shaped body comprising:
 a shaped body; and 
 a coating comprising:
 (a) vermiculite; 
 (b) polymer capable of forming a film, said polymer comprising polyvinyl alcohol, ethyl vinyl alcohol copolymer, or blends thereof; 
 (c) dispersion agent for the vermiculite in the polymer, said dispersion agent being an anionic wax; and 
 (d) cross-linking agent; 
 wherein the weight ratio of dispersion agent to vermiculite is about 0.02 to about 0.45. 
 
 
     
     
       21. The coated shaped body of  claim 20 , wherein said anionic wax is anionic polyethylene wax, anionic paraffin wax, anionic carnauba wax, or blends thereof. 
     
     
       22. The coated shaped body of  claim 20 , wherein said anionic wax is anionic carnauba wax or a blend of anionic carnauba wax and anionic polyethylene wax. 
     
     
       23. The coated shaped body of  claim 20 , wherein said anionic wax is a blend of anionic paraffin wax and anionic polyethylene wax. 
     
     
       24. The coated shaped body of  claim 20 , wherein the polymer comprises polyvinyl alcohol. 
     
     
       25. The coated shaped body of  claim 20 , wherein the polymer comprises ethyl vinyl alcohol copolymer.